Optically readable thin film digital data storage medium

ABSTRACT

An optically readable data storage medium includes a thin film data carrier fabricated from first and second juxtaposed plastic layers. A microembossed data surface is positioned within an interface zone and includes physically displaced surface elements which encode digital data. An adaptor temporarily receives and supports the thin film data carrier from below and includes a centrally located aperture geometrically compatible with a standard CD player spindle to enable the adaptor to be supported and rotated by the spindle. The adaptor includes a refraction zone having an area and a location underlying the microembossed data surface to enable the light beam from the light source of the CD player to be focussed onto the rotatable data surface. The reflected light beam modulated by the digital data encoded within the microembossed data surface is intercepted and converted to an electrical signal by the CD player optical readout device.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to optically readable digital data storage media,and more particularly, to optically readable thin film digital datastorage media adapted to be compatible with CD audio and CD ROM playingequipment.

2. Description of the Prior Art

Compact discs or CD's have the capability of storing approximately 600megabytes of digitized audio signals (CD audio) or digital data in acomputer readable format (CD ROM).

Conventional CD discs are fabricated as standard-size rigid plasticdiscs by means of a mold-based replication system using injectionmolding techniques. Such CD manufacturing techniques have the capabilityof producing CD discs at the rate of only approximately twenty units perminute per mold. As a result of this relatively slow production rate,the cost of producing CD's is relatively high. The essentiallyall-plastic composition of CD's requires the consumption of a relativelysignificant amount of plastic during the manufacturing process.

Each CD includes a series of either circular or spiral data tracks whichare illuminated and read by a source of coherent light such as a laser.The layer of rigid plastic positioned between each data track and thesource of coherent light provides structural rigidity, protects the datatracks, and also functions as a single element, integral lens elementhaving a forty-seven millimeter optical path length to refract and focusthe coherent light beam onto a selected data track.

The relatively high cost of the CD plastic content and the slowinjection molding production techniques involved in mass producing CD'shas maintained the cost of this digital data storage medium relativelyhigh.

SUMMARY OF THE INVENTION

It is a primary object of the present invention to provide a thin filmdigital data storage medium which can be duplicated at high speed byspecialized microembossing techniques involving the use of a masterembossing drum including a series of laterally spaced apartmicroembossing shims or masters permitting the simultaneous reproductionof multiple copies of a single microembossed master onto a web of lowcost thin film material.

Another object of the present invention is to provide a thin filmdigital data storage medium which utilizes a thin film data carrier incombination with a reusable adaptor which temporarily receives andsupports the data carrier from below and which simultaneously interfacesthe data carrier with both the optical and physical geometry of aconventional CD player.

Still another object of the present invention is to provide a thin filmdigital data storage medium which can be mass-produced at a productionrate in excess of thirty times the production rate of conventional CD's.

Still another object of the present invention is to provide a thin filmdigital data storage medium which can either be permanently ortemporarily laminated to a card to facilitate storage and handling.

Briefly stated, and in accord with one embodiment of the invention, athin film digital data storage medium is provided for a CD player havinga centrally located spindle for supporting and rotating a CD havingplanar upper and lower surfaces. The thin film digital data storagemedium includes a series of embedded data tracks each including encodeddigital data. The data readout system of the CD player includes a sourceof coherent light positioned below the CD for generating a light beam tosequentially illuminate each data track to produce a reflected lightbeam modulated by the encoded digital data to be intercepted andconverted to a corresponding electrical signal by an optical readoutdevice.

The thin film digital data storage medium includes a thin film datacarrier including a first layer, a second layer and a microembossed datasurface. The first layer is formed from a plastic material having adefined thickness and first and second opposing surfaces. The secondlayer is formed from a second optically transparent plastic materialhaving a first index of refraction and first and second opposingsurfaces defining a first thickness for providing a secondary refractionzone. The first surface of the second layer is positioned adjacent toand is joined to the second surface of the first layer to define aninterface zone located in proximity to those joined surfaces. Themicroembossed data surface is formed within the interface zone andincludes physically displaced surface elements with an elevation varyingrelative to the undisplaced surface elements to encode digital data. Theadaptor also includes a secondary refraction zone formed from a secondoptically transparent material having a second index of refraction andfirst and second parallel opposing surfaces defining a second thickness.The secondary refraction zone includes an area related to the area ofthe microembossed data surface and a location underlying themicroembossed data surface. Sequential transmission of the light beamthrough the primary refraction zone of the adaptor and through thesecondary refraction zone of the thin film data carrier focusses thelight beam onto the microembossed data surface to produce a reflectedlight beam modulated by the digital data encoded within themicroembossed data surface for interception and conversion into acorresponding electrical signal by the CD player optical readout device.

DESCRIPTION OF THE DRAWINGS

The invention is pointed out with particularity in the appended claims.However, other objects and advantages together with the operation of theinvention may be better understood by reference to the followingdetailed description taken in connection with the followingillustrations, wherein:

FIG. 1 represents an elevational view of a trading card version of thethin film data carrier of the present invention.

FIG. 2 illustrates a peel and play embodiment of the thin film datacarrier of the present invention temporarily secured to a semi-rigidpaper or plastic backing.

FIG. 3A illustrates a laminated embodiment of the thin film data carrierof the present invention with the microembossed data surface exposed.

FIG. 3B illustrates a laminated version of the thin film data carrier ofthe present invention with the microembossed data surface located in aninterface zone within the laminated structure.

FIG. 3C illustrates a single layer embodiment of the thin film datacarrier with the microembossed data surface exposed.

FIG. 3D illustrates a single layer embodiment of the thin film datacarrier of the present invention with the microembossed data surfacereversed relative to its position as illustrated in FIG. 3C.

FIG. 3E illustrates the FIG. 3A embodiment of the thin film data carrierof the present invention supported by an adaptor.

FIG. 3F illustrates the FIG. 3B embodiment of the thin film data carrierof the present invention supported by an adaptor.

FIG. 3G illustrates the FIG. 3C embodiment of the thin film data carrierof the present invention supported by an adaptor.

FIG. 3H illustrates the FIG. 3D embodiment of the thin film data carriersupported by an adaptor.

FIG. 4 illustrates one embodiment of an adaptor for the thin film datacarrier of the present invention.

FIG. 5 illustrates a trading card embodiment of the thin film datacarrier supported by the adaptor illustrated in FIG. 4.

FIG. 6 illustrates a second embodiment of the adaptor including a recessfor receiving the thin film data carrier.

FIG. 7 illustrates the FIG. 6 adaptor receiving a thin film datacarrier.

FIG. 8 illustrates the opposite side of the embodiment of the inventionillustrated in FIG. 1.

FIG. 9 represents a sectional view of the trading card embodiment of thethin film data carrier illustrated in FIG. 8.

FIG. 10 illustrates another embodiment of the trading card embodiment ofthe thin film data carrier having a perforated, removable aperture.

FIG. 11 represents an elevational view of the embodiment of theinvention illustrated in FIG. 10.

FIG. 12 illustrates another embodiment of the thin film data carrier ofthe present invention.

FIG. 13 illustrates a view from below of the embodiment of the inventionillustrated in FIG. 12.

FIG. 14 represents an elevational view showing the FIG. 12 embodiment ofthe invention supported by an adaptor.

FIG. 15 illustrates the FIG. 2 peel and play embodiment of the thin filmdata carrier of the present invention showing its relationship to anadaptor.

FIG. 16 illustrates a sectional view of the embodiment of the inventionillustrated in FIG. 15 installed on an adaptor.

FIG. 17 illustrates one configuration of the peel and play embodiment ofthe thin film data carrier installed on an adaptor.

FIG. 18 illustrates a second embodiment of the peel and play embodimentof the thin film data carrier installed on an adaptor.

FIGS. 19-22 represent a series of drawings illustrating a rotationallocking device forming a part of the adaptor of the present invention.

FIG. 23 illustrates a peel and play embodiment of the thin film datacarrier of the present invention including a locking tab compatible withthe locking device of the adaptor embodiment illustrated in FIGS. 19-22.

FIG. 24 illustrates a trading card embodiment of the thin film datacarrier of the present invention having a locking tab compatible withthe rotational locking device illustrated in the adaptor depicted inFIGS. 19-22.

FIGS. 25A, 25B and 25C illustrate three additional embodiments of thethin film data carrier.

FIG. 26 illustrates a flow chart outlining the steps necessary toduplicate conventional CD's using injection molding techniques.

FIG. 27 represents a flow chart outlining the sequential series of stepswhich may be utilized to replicate different embodiments of the thinfilm digital data storage medium of the present invention.

FIG. 28 illustrates a plastic web being microembossed with threelaterally displaced data sets.

FIG. 29 illustrates a thin film digital data storage medium having ashape or perimeter configured to replicate the head of an animal.

FIG. 30 illustrates a specific procedure for manufacturing the thin filmdigital data storage medium of the present invention and affixing thecompleted product to a magazine page.

FIGS. 31A, 31B and 31C illustrate procedures for laminating andde-laminating a thin film digital data storage medium to a sheet ofpaper or magazine page.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In order to better illustrate the advantages of the invention and itscontributions to the art, various preferred physical embodiments of theinvention will now be described in detail.

As illustrated in FIGS. 1 and 2, the thin film digital data storagemedium 10 may be configured as a self-supporting card 12 or may beconfigured either as a non-rigid or semi-rigid element 10 removablysecured to a semi-rigid support sheet 14.

FIG. 3A illustrates a first embodiment of a thin film data storagemedium of the present invention in which a data carrier 16 includes afirst layer 18 laminated or otherwise joined to a second layer 20. Firstlayer 18 serves as a support layer and includes a first surface 22 and aplanar, spaced apart second surface 24. Second layer 20 serves as anembossed thin film data layer and includes a first surface 26 and aplanar, spaced apart second surface 28. First layer or support layer 18may be fabricated from a 2-7 mil thick, semi-rigid plastic material suchas polyester or synthetic paper. Second layer or thin film data layer 20may be fabricated from a 2-7 mil layer of optically transparentembossable plastic material having a first index of refraction. In theFIG. 3A embodiment, second surface 28 of thin film data layer 20 isformed as a microembossed data surface.

FIG. 3B illustrates a second embodiment of a two-layer thin film digitaldata storage medium where data carrier 16 includes a then film datalayer 20 fabricated from a 2-7 mil or thicker layer of embossableplastic material such as a polycarbonate having a first surface 26formed as a microembossed data surface and an opposing second surface28. In the FIG. 3B alternative embodiment, the relative position of themicroembossed data surface has been reversed relative to the orientationillustrated in FIG. 3A.

FIG. 3C illustrates a third alternative embodiment of the inventionwhere data carrier 16 is fabricated with second layer or thin film datalayer 20 without first layer 18. In the FIG. 3C embodiment of theinvention, second surface 28 is formed as the microembossed datasurface. To provide a reasonable degree of rigidity, the FIG. 3C singlelayer data carrier 16 may be fabricated from a semi-rigid plasticmaterial such as a polycarbonate having a thickness on the order ofabout 11 mils.

FIG. 3D illustrates a fourth embodiment of the invention which is formedas a single layer data carrier 16. In the FIG. 3D embodiment, firstsurface 26 includes the microembossed data surface.

Any of the FIG. 3 embodiments of the invention will work acceptably, butadditional protection for the microembossed data surface is provided bythe FIG. 3B embodiment. A thin hard coat may be applied as a curableliquid to either or both exposed outer surfaces of the laminated orunlaminated materials illustrated in FIG. 3 to enhance the scratchresistant character of the system.

The preferred technique for microembossing digital data into theappropriate surface is disclosed in U.S. Pat. No. 4,836,874(Foster)which is hereby incorporated by reference. Spectratek of Los Angeles,Calif. implements appropriate microembossing procedures for commercialcustomers.

A wide variety of data categories in various data formats may beembossed into and stored on the thin film digital data storage medium ofthe present invention by utilizing the techniques disclosed in the '874patent. For sports trading card applications of the type illustrated inFIG. 1, digital data consisting of visual information includingphotographs or video, textual information including player biographicalinformation, statistics, historical information, other data as well asmusic can be stored and recalled at will. Since the data storage formatdiffers from CD audio data as opposed to CD ROM data, the thin filmdigital data storage medium of the present invention may be formatted ineither of these formats or in any other currently available orsubsequently developed data storage format.

Because it is a primary object of the present invention to provide athin film digital data storage medium which can be rendered compatiblewith existing CD audio or CD ROM playing equipment, an adaptor 30 of thetype illustrated in FIGS. 4 and 5 represents a necessary second elementof the invention. As shown in FIG. 5, a source of coherent lighttypically taking the form of a laser 32 generates a coherent light beam34 which must be sharply focussed on a specific data track intended tobe read out by the CD hardware. When the selected data track is properlyilluminated by the focussed coherent light beam 34, that beam produces areflected light beam modulated by the encoded digital data which isdirected to and intercepted by a conventional optical readout device(not shown) to convert the reflected light beam modulated by the encodeddigital data into a corresponding electrical signal which is thendecoded and read by a microprocessor-based decoding system. With priorart CD hardware, a lens positioned in the optical path of laser 32partially converges the laser output beam while the remaining opticalconverging function is performed by the rigid optically transparent,refractive plastic layer of the CD which encapsulates the CD datatracks. That relatively thick plastic layer used with conventional CDproducts provides the necessary structural rigidity and maintains therequisite planar relationship between the upper and lower surfaces ofthe CD disc itself.

Because the thin film digital data storage medium of the presentinvention lacks complete structural rigidity and at best can bedescribed as a semi-rigid medium, adaptor 30 is supplied as a secondelement of the system to perform the essential functions of 1) assistingin focussing the incoming laser beam, 2) assisting in focussing theoutgoing laser data readout beam, 3) forming an essentially rigid,planar reference surface to maintain the laser beam focussed on theembossed thin film data tracks, 4) aligning the data storage mediumrelative to the adaptor, and 5) providing the structure necessary toalign the adaptor relative to the CD player. If the adaptor is notconfigured to perform all five functions, a conventional CD player willnot be able to read out the data encoded in the thin film digital datastorage medium.

As illustrated in FIGS. 6 and 7, the upper surface of adaptor 30 mayinclude a rectangular recess having a depth configured to receive thecomposite thickness of a thin film data card in the form of a plastic orthick paper trading card 12 such that the upper surface of card 12 doesnot extend above the upper surface 36 of adaptor 30.

As illustrated in FIG. 1, thin film digital data storage medium 10 maybe formed as a trading card 12. The central area of data carrier 16includes a circular aperture 40 dimensioned to accommodate a CD drivespindle 42 as illustrated in FIGS. 5 and 7. The outer limit of datacarrier 16 is defined by circular perimeter 44. The microembossed datasurface is confined to the limits of data carrier 16 lying betweenaperture 40 and perimeter 44. For a standard 21/2"×31/2" sports tradingcard, the maximum data storage capacity of the resulting data surfaceapproximates 64 megabytes using current data formats.

As illustrated in FIG. 5, the overall thickness of adaptor 30 may beconfigured to approximate the overall thickness of the refractingelement of a conventional CD. FIGS. 3E-3H illustrate how the variousembodiments of data carrier 16 shown in FIGS. 3A-3D may be coupled to anadaptor to sharply focus coherent light beam 34 from laser 32 at theprecise elevation where the data tracks are located.

FIG. 3E illustrates the FIG. 3A embodiment of the invention positionedon the upper surface of adaptor 30 with the microembossed data surfaceadjacent to the upper surface of adaptor 30. For any one of the fourFIG. 3E-3H embodiments of the invention, a semi-rigid peel and playbacking 14 may be either temporarily or permanently bonded to the upper,exposed surface of data carrier 16.

FIG. 3F illustrates the FIG. 3B embodiment of the invention placed onthe upper surface of adaptor 30. FIGS. 3G and 3H illustrate respectivelythe FIG. 3C and 3D embodiments of the invention supported by adaptor 30.

Because of the different relative elevation of the microembossed datasurface in each of the different embodiments of the inventionillustrated in FIGS. 3E-3H, the relative thickness and index ofrefraction of the transparent plastic material used to fabricate adaptor30 may be adjusted as necessary to properly focus coherent light beam 34onto the data tracks of the microembossed data surface by providing atotal optical path length equivalent to the 47 mm optical path length ofa conventional CD. A greater degree of convergence or refraction must beachieved by the refraction zone of adaptor 30 in the FIG. 3E and 3Gembodiments since the microembossed data surface directly contacts theupper surface of adaptor 30. In the FIG. 3F and 3H embodiments, layer 20partially refracts light beam 34 and helps focus it on the data tracks.In those embodiments, the thickness of adaptor 30 will be reduced.

As illustrated in FIG. 6, the upper surface of adaptor 30 may include arecess compatible with the geometry of the member to be inserted withinthat recess. For the trading card embodiment of the inventionillustrated in FIG. 1 having a 21/2"×31/2" exterior dimension, recess 50will have corresponding dimensions and an appropriate depth. Inaddition, to remain compatible with conventional CD playback hardware,adaptor 30 must include a centrally located aperture 52 geometricallycompatible with CD player spindle 42. Additional coupling betweenadaptor 30 and the relevant CD hardware may be provided in such hardwareby a contact mechanism 54, typically spring-biased, as illustrated inFIGS. 6 and 7 which provides enhanced frictional contact between spindle42 and the abutting surface of carrier 30 as well as between the exposedsurface of trading card 12 and the abutting surfaces of contactmechanism 54.

In the trading card embodiment of the thin film digital data storagemedium illustrated in FIGS. 1, 5, 8 and 9, aperture 40 extends entirelythrough thin film data carrier 16. FIGS. 10 and 11 illustrate a secondembodiment of the invention having a perforated or partially die cutcircular central section 56 designed to be readily removed prior toinstallation of trading card 12 on adaptor 30. The provision ofperforated or partially die cut section 56 or an equivalent removablecentral section having either a reduced thickness or a reduced strengthperimeter or being formed from a reduced strength material allows forthe uninterrupted display of pictorial or text information on the uppersurface of trading card 12 as illustrated in FIG. 10 as long as the cardremains in its original condition prior to the removal of section 56.The diameter of section 56 is adjusted to accommodate spindle 42 of theCD player.

In the second alterative embodiment of the trading card version of theinvention illustrated in FIGS. 12, 13 and 14, data carrier 16 issupported by the upper surface of adaptor 30. Spindle 42 fits within thecentrally located aperture of adaptor 30, but does not extend througheither card 12 or data carrier 16. This particular embodiment of theinvention requires a non-standard spindle configuration and may not becompatible with existing CD player hardware.

FIGS. 2 and 15-18 illustrate the peel and play version of the thin filmdata storage medium which is not necessarily self-supporting as was thecase with the previously described trading card embodiment of theinvention. As illustrated in FIG. 2, thin film digital data storagemedium 10 is temporarily coupled to support sheet 14 by a specific formof adhesive well known to those skilled in the relevant art which allowsthin film element 10 to be temporarily attached to semi-rigid supportmember 14 such as a plastic or paper postcard-type insert in a magazine.Immediately prior to use, thin film 10 is peeled away and removed fromsheet 14 and, as illustrated in FIGS. 15 and 16, is placed on the uppersurface a specially configured adaptor 30.

FIGS. 16, 17 and 18 illustrate that, as was the case with the systemillustrated in FIGS. 3C and 3D, layer 18 may be positioned either withthe microembossed data surface down as illustrated in FIG. 17 or up asillustrated in FIG. 18. In each case, either the index of refraction ofadaptor refraction zone 48 or the thickness of adaptor 30 must beadjusted to precisely converge light beam 34 onto the data tracks ofdata surface 26.

In the preferred embodiment of the invention, an adaptor to data carrierrotational coupling structure of the type illustrated in FIGS. 19-24should be provided to prevent or minimize relative rotation betweenadaptor 30 and thin film 10. FIGS. 19-22 illustrate that adaptor 30 maybe modified to include a rotational locking device 58 which is coupledto and extends above the adaptor upper surface 60 and at least partiallysurrounds aperture 52. Locking device 58 includes a slot 60 having anopening 62 and a closed end section 64 for receiving a rotationallocking element such as a tab 66 which protrudes in an inward directionfrom aperture 40 of the two different thin film embodiments illustratedin FIGS. 23 and 24.

When thin film 10 is loaded into adaptor 30, tab 66 is carefully alignedwith opening 62 so that an initial relative rotation as may occur duringstartup of the CD player between thin film 10 and adaptor 30 in theproper direction will cause tab 66 to rotate to a position which abutsthe end 68 of slot 60 to effectively lock together thin film 10 andadaptor 30.

As illustrated in FIGS. 19 and 20, rotational locking device 58 may beinjection molded separately from adaptor 30 and snapped into adaptor 30which will typically be die cut in the desired shape from a rectangularplastic sheet. An abrasion resistant hard coat may be added to either orboth surfaces of the plastic sheet prior to die cutting.

Referring now to FIGS. 25A-C, three additional embodiments of theinvention will now be described in detail. FIG. 25A illustrates anembodiment of a thin film data carrier which includes first layer orthin film data layer 18 fabricated from 1 mil embossed polyester vacuumdeposited film. Second layer or support layer 20 is fabricated from 10mil transparent polycarbonate which provides a secondary refraction zonebetween first and second surfaces 22 and 24 as indicated by the arrowdesignated by reference number 92. Reference number 96 illustrates theinterface zone located in proximity to the junction between theadjacent, joined surfaces of first layer 18 and second layer 20 in whichmicroembossed data surface 90 is formed. As illustrated in FIG. 25A,data surface 90 is formed in the lower, vacuum metallized surface offirst layer 18.

Adaptor 30 is formed from acrylic plastic having a defined thicknesswhich as illustrated by the arrow designated by reference number 94forms a primary refraction zone.

Because conventional CD's provide an optical path length of 47millimeters, the optical path length provided by the combined effect ofthe primary and secondary refractive zones of the present invention mustbe substantially equal to that 47 millimeter path length standard toallow the system of the present invention to be used with conventionalCD players.

In the FIG. 25B embodiment of the invention, microembossed data surface90 is formed on the lower or second surface of first layer 18 within theinterface zone 96 which couples first layer 18 with second layer 20. Inthis embodiment of the invention, first layer 18 is formed from aflexible 8 to 12 mil plastic film fabricated from polyester, polyvinylchloride, polycarbonate or an equivalent material. In this embodiment ofthe invention, the digital data is embossed directly into the secondsurface of first layer 18 which may be subsequently vacuum depositedwith a reflective metal such as aluminum. Second layer 20 is provided byforming a thin coating of a low bi-refringence thermoset plastic overmicroembossed data surface 90.

Referring now to FIG. 25C, microembossed data surface 90 is formed inthe upper or first surface of second layer 20 which may be fabricatedfrom a relatively thin plastic film such as a film having a thickness offrom about 8 mils to about 12 mils. Following the embossing operation,microembossed data surface 90 is covered with a thin protective coatingof thermoset plastic. No special thickness, optical characteristic orother property is required for protective coating layer 18 because itserves neither as the primary or secondary refraction zone. Second layer20, however, does perform a refracting function and requires a materialhaving a low bi-refringence characteristic.

For most applications, microembossed data surface 90 will be formed as apart of a vacuum deposited layer of reflective metal such as aluminumeither prior to or subsequent to the embossing operation. Such vacuumdeposition procedures are well known to those of ordinary skill in theart.

FIG. 26 outlines the sequence of steps generally required to fabricateprior art single piece CD's which, using current technology, typicallyresult in a production rate limited to approximately twenty CD units perinjection molding cavity per minute. FIG. 27 summarizes productiontechniques which may be utilized in producing thin film digital datastorage media according to the present invention. The FIG. 26 and 27steps of laser mastering and electro-forming are well known to those ofodinary skill in the relevant art. Preparation of an appropriate form ofembossing shim for microembossing digital data into the thin film of thepresent invention represents technology commercially available fromSpectratek of Los Angeles, Calif. The FIG. 27 metalizing step vacuumdeposits a thin layer of aluminum onto the microembossed data surface toenhance the reflectivity of that surface. The optional FIG. 27lamination step is implemented only when the two layer embodiment of theinvention illustrated in FIGS. 3A and 3B is used. The full upper surfacearea of the thin film digital data storage medium may be printed usingconventional web printing techniques to display either images, text orboth. The lower surface outside data zone 46 may also be printed.

FIG. 28 illustrates that an appropriate form of embossing shim 70 may bewrapped around and coupled to a cylindrical embossing roller 72 which,using the unique techniques disclosed in the '874 patent as commerciallypracticed by Spectratek of Los, Angeles, Calif., yields a highlyfaithful reproduction of the relevant digital data on the exposedsurface of plastic sheet material 74. The width of web 74 may readily bevaried from about six inches to produce a width replication of a fullsize CD to a width of at least forty inches to simultaneously producenumerous laterally spaced apart duplicates of the microembossed patternof embossing shim 70 as illustrated in FIG. 28.

Using the techniques disclosed in the '874 patent in combination withthe multiple width data embossing techniques illustrated in FIG. 28,replication of the thin film digital data storage medium can be readilybe accomplished at production rates of at least 720 units per minute, arate substantially exceeding the twenty unit per minute production ratelimit of conventional injection molded CD's. It is anticipated that thisthin film production rate can be significantly enhanced.

To use the thin film digital data storage medium of the presentinvention, a customer typically purchases a single adaptor 30 which canbe reused numerous times to read out the data stored on any one of avariety of compatible thin film products. Enhanced, potentially highercost versions of adaptor 30 may include a hard coating 78 on either orboth the upper and lower surfaces of the adaptor as illustrated in FIG.22 to resist scratching which over a period of time might ultimatelydegrade the accuracy of the digital data readout.

As a result of the requirement to purchase only a single adaptor for usewith a nearly unlimited number of thin film data storage media, theplastic content of the thin film product has been dramatically reducedand the manufacturing cost of such thin film products has been decreasedto a level significantly below the cost of producing conventional CD's.

While the data storage capacity of a thin film product in the format ofa 21/2"×31/2" trading card may be limited to only 64 megabytes, thesubstantially larger peel and play version of the thin film product iscapable of storing the same 600 megabyte digital data capacity as aconventional CD.

Because adaptor 30 also serves the function of centering the thin filmsystem relative to CD playback hardware and provides an area having aplanar surface for receiving and maintaining the thin film system in aflat configuration aligned with the relevant CD player geometry, theactual perimeter configuration of the thin film system or its "shape" isrelatively unimportant. For example, as illustrated in FIG. 29, theperimeter of a thin film product 10 may be configured as a circle, asquare, a rectangle, a triangle, a star, an animal head or in any of avirtually limitless variety of different geometric shapes. Foradvertising and promotional applications, such shape flexibilityrepresents a significant benefit.

Referring now to FIGS. 30 and 31A, a die cutting process utilizing closetolerance male and female tooling sequentially die-cuts previouslyembossed thin film digital data storage media 10 into the desired endproduct shape. Reference number 80 designates the male die. The femaledie is not shown. Rotary die cutting of the digital data storage media10 may represent an alternative process. Carrier sheet 82 temporarilyretains support carrier 86 and media 10 while the remainder of web 74generally referred to as the "ladder" is wound onto take-up roll 84.Carrier 86 includes an upper surface attached to the lower surface ofdigital data storage medium 10 with a first form of adhesive whichtemporarily bonds medium 10 to support carrier 86. The opposite surfaceof support carrier 86 includes a more permanent form of adhesive.

As illustrated in FIGS. 30 and 31B, the use of a conventional air labelapplication system pneumatically separates digital data storage medium10 and support carrier 86 from carrier sheet 82 and directs data storagemedium 10 and support carrier 86 through the air and onto the exposedupper surface of a receiving sheet such as magazine page 88. FIG. 31Billustrates data storage medium 10 and support carrier 86 attached tomagazine page 88.

As illustrated in FIG. 31C, the releasable adhesive applied to the uppersurface of support carrier 86 allows a consumer to readily peel back andremove the embossed digital data storage medium 10 from magazine page88. Numerous other methods of distributing and using the digital datastorage medium of the present invention would be readily apparent tothose skilled in the relevant art in view of the present disclosure.

It will be apparent to those skilled in the art that the disclosed thinfilm digital data storage medium may be modified in numerous ways andmay assume many embodiments other than the preferred forms specificallyset out and described above. For example, the thin film digital datastorage medium and adaptor system may also be used for video discapplications as well as CD's. Accordingly, it is intended by theappended claims to cover all such modifications of the invention whichfall within the true spirit and scope of the invention.

We claim:
 1. A semi-rigid thin film digital data storage medium for usewith a CD player with a centrally located spindle for supporting androtating a standard CD having planar upper and lower surfaces andembedded data tracks consisting of encoded digital data, the CD playerhaving a data readout system including a source of coherent lightpositioned below the CD for generating a light beam to sequentiallyilluminate each data track to produce a reflected light beam modulatedby the encoded digital data to be intercepted and converted to acorresponding electrical signal by an optical readout device, the thinfilm digital data storage medium comprising:a. a semi-rigid,self-supporting composite data carrier having a first area andincludingi. an optically transparent support layer formed from a stiff,semi-rigid material having a defined thickness and first and secondopposing planar surfaces for providing a secondary refraction zone, ii.a thin film data layer formed from a web of flexible, non-selfsupporting plastic film having a first surface and an opposing inkprintable second surface, the first surface of the thin film data layerpositioned adjacent to and bonded to the second surface of the supportlayer; b. an optically reflective microembossed data surface formed onthe first surface of the thin film data layer within a data zone andhaving a series of spaced apart, displaced surface elements with anelevation offset relative to undisplaced surface elements to encodedigital data, the secondary refraction zone of the support layerconfigured to receive and partially converge the CD player light beambut having insufficient refractive power to directly focus the lightbeam onto the microembossed data surface; and c. a first visual mediazone formed on the ink printable second surface of the thin film datalayer for receiving and displaying a visually perceptible image ortextual information.
 2. The thin film digital data storage medium ofclaim 1 wherein the data carrier includes a non-circular perimeter. 3.The thin film digital data storage medium of claim 2 wherein thestandard CD includes a second area, and wherein the first area of thedata carrier is less than the second area of the standard CD.
 4. Thethin film digital data storage medium of claim 3 wherein the datacarrier includes a rectangular perimeter and wherein the microembosseddata surface is formed within a circular data zone.
 5. The thin filmdigital data storage medium of claim 1 wherein the first surface of thesupport layer represents an ink printable surface and wherein the datacarrier includes a second visual media zone on the first surface of thesupport layer outside the data zone for receiving and displaying avisually perceptible image or textual information.
 6. The thin filmdigital data storage medium of claim 1 wherein the data carrier includesa non-circular perimeter, wherein the standard CD includes a secondarea, wherein the first area of the data carrier is less than the secondarea of the standard CD, wherein the data carrier includes a rectangularperimeter, and wherein the microembossed data surface is formed within acircular data zone.
 7. The thin film digital data storage medium ofclaim 1 wherein the data carrier includes an aperture geometricallycompatible with the CD player spindle.
 8. The thin film digital datastorage medium of claim 1 wherein the data carrier includes a removablecentral section capable of forming an aperture geometrically compatiblewith the CD player spindle.
 9. The thin film digital data storage mediumof claim 8 wherein the removable central section of the data carrier isformed by a series of perforations in the data carrier.
 10. The thinfilm digital data storage medium of claim 1 wherein the conventional CDincludes an optical path length of 47 millimeters and wherein thesecondary refraction zone of the support layer includes an optical pathlength substantially less than 47 millimeters.
 11. The thin film digitaldata storage medium of claim 1 further including a metallized layerdisposed on the first surface of the thin film.
 12. The thin filmdigital data storage medium of claim 11 wherein the metallized layerincludes a vacuum deposited metallic film.
 13. The thin film digitaldata storage medium of claim 1 further including a transparent,protective hard coat formed on the first surface of the support layer.14. The thin film digital data storage medium of claim 1 furtherincluding a transparent, protective hard coat formed on the secondsurface of the thin film data layer.
 15. A method for manufacturing asemi-rigid thin film digital data storage medium for use with a CDplayer having a centrally located spindle for supporting and rotating astandard CD having planar upper and lower surfaces and embedded datatracks consisting of encoded digital data, the CD player having a datareadout system including a source of coherent light positioned below theCD for generating a light beam to sequentially illuminate each datatrack to produce a reflected light beam modulated by the encoded digitaldata to be intercepted and converted to a corresponding electricalsignal by an optical readout device, comprising the steps of:a.providing an optically transparent support layer formed from a stiff,semi-rigid material having a defined thickness and first and secondopposing surfaces defining a secondary refraction zone; b. providing athin film of flexible, non-self supporting plastic having a firstsurface and an opposing ink printable second surface; c. microembossingthe first surface of the thin film within a data zone to create a seriesof spaced apart, displaced surface elements with an elevation offsetrelative to undisplaced surface elements to form a data surfacerepresenting encoded digital data; and d. forming a semi-rigid,self-supporting composite digital data storage medium by bonding thefirst surface of the non-self supporting thin film to the second surfaceof the semi-rigid support layer, wherein the secondary refraction zoneof the support layer is configured to receive and partially converge theCD player light beam but possesses insufficient refractive power todirectly focus the CD player light beam onto the microembossed datasurface.
 16. The method of claim 15 including the further step ofimprinting the second surface of the thin film with a visuallyperceptible image or textual information.
 17. The method of claim 16including the further step of forming a light reflecting metal layer onthe first surface of the thin film.
 18. The method of claim 16 whereinthe metal layer forming step is performed after the microembossing step.19. The method of claim 15 including the further step of passing a laserbeam through the second surface of the thin film and focussing the laserbeam on the first surface of the thin film to locally heat the firstsurface while simultaneously performing the microembossing step.
 20. Themethod of claim 18 including the further step of passing a laser beamthrough the second surface of the thin film and focussing the laser beamon the first surface of the thin film to locally heat the first surfacewhile simultaneously performing the microembossing step.
 21. The methodof claim 20 including the further step of applying a thin coating of acolored dye along the first surface of the thin film and selecting alaser which emits an output beam having a color complementary to the dyecolor to cause the laser output beam to be absorbed by the dye inproximity to the first surface of the thin film to heat and soften thatsurface to facilitate the microembossing step.
 22. The method of claim17 wherein the microembossed data zone includes a perimeter andincluding the further step of cutting the composite digital data storagemedium into individual units where each unit includes a microembosseddata zone and a perimeter lying outside the data zone perimeter.
 23. Themethod of claim 22 including the further step of cutting the digitaldata storage medium into units having a non-circular perimeter.
 24. Themethod of claim 23 including the further step of cutting the digitaldata storage medium into units having a rectangular perimeter.
 25. Themethod of claim 24 including the further step of ink printing the secondsurface of the thin film with a photographic image.
 26. The method ofclaim 25 including the further step of ink printing the second surfaceof the thin film with the photographic image of a person.
 27. The methodof claim 22 wherein the first surface of the support layer includes anink printable surface and including the further step of imprinting thefirst surface of the support layer with a visually perceptible image ortextual information.
 28. The method of claim 22 wherein the imprintingstep is performed on the first surface of the support layer outside ofthe data zone.
 29. A semi-rigid thin film digital data storage mediumfor use with a CD player and an adaptor, the CD player having acentrally located spindle for supporting and rotating a standard CDhaving planar upper and lower surfaces and embedded data tracksconsisting of encoded digital data, the adaptor having a primaryrefraction zone, a centrally located aperture compatible with the CDplayer spindle for aligning the adaptor relative to the player andconfigured to support the digital data storage medium from below, the CDplayer having a data readout system including a source of coherent lightpositioned below the CD for generating a light beam to sequentiallyilluminate each data track to produce a reflected light beam modulatedby the encoded digital data to be intercepted and converted to acorresponding electrical signal by an optical readout device, the thinfilm digital data storage medium comprising:a. a semi-rigid,self-supporting composite data carrier having a first area andincludingi. an optically transparent support layer formed from a stiff,semi-rigid material having a defined thickness and first and secondopposing planar surfaces for providing a secondary refraction zone, ii.a thin film data layer formed from a web of flexible, non-selfsupporting plastic film having a first surface and an opposing inkprintable second surface, the first surface of the thin film data layerpositioned adjacent to and bonded to the second surface of the supportlayer; b. an optically reflective microembossed data surface formed onthe first surface of the thin film data layer within a data zone andhaving a series of spaced apart, displaced surface elements with anelevation offset relative to undisplaced surface elements to encodedigital data, the secondary refraction zone of the support layerconfigured to receive and refract the CD player light beam after it haspassed through and been partially converged by the adaptor primaryrefractive zone to further converge and to focus the light beam onto themicroembossed data surface; and c. a first visual media zone formed onthe ink printable second surface of the thin film data layer forreceiving and displaying a visually perceptible image or textualinformation.
 30. The thin film digital data storage medium of claim 29wherein the data carrier includes a non-circular perimeter.
 31. The thinfilm digital data storage medium of claim 29 wherein the standard CDincludes a second area, and wherein the first area of the data carrieris less than the second area of the standard CD.
 32. The thin filmdigital data storage medium of claim 29 wherein the data carrierincludes a rectangular perimeter and wherein the microembossed datasurface is formed within a circular data zone.
 33. The thin film digitaldata storage medium of Claim 29 wherein the first surface of the supportlayer represents an ink printable surface and wherein the data carrierincludes a second visual media zone on the first surface of the supportlayer outside the data zone for receiving and displaying a visuallyperceptible image or textual information.
 34. The thin film digital datastorage medium of claim 29 wherein the data carrier includes anon-circular perimeter, wherein the standard CD includes a second area,wherein the first area of the data carrier is less than the second areaof the standard CD, wherein the data carrier includes a rectangularperimeter, and wherein the microembossed data surface is formed within acircular data zone.
 35. The thin film digital data storage medium ofclaim 29 wherein the data carrier includes an aperture geometricallycompatible with the CD player spindle.
 36. The thin film digital datastorage medium of claim 29 wherein the data carrier includes a removablecentral section capable of forming an aperture geometrically compatiblewith the CD player spindle.
 37. The thin film digital data storagemedium of claim 29 wherein the removable central section of the datacarrier is formed by a series of perforations in the data carrier. 38.The thin film digital data storage medium of claim 29 wherein theconventional CD includes an optical path length of 47 millimeters andwherein the secondary refraction zone of the support layer includes anoptical path length substantially less than 47 millimeters.
 39. The thinfilm digital data storage medium of claim 29 further including ametallized layer disposed on the first surface of the thin film.
 40. Thethin film digital data storage medium of claim 39 wherein the metallizedlayer includes a vacuum deposited metallic film.
 41. The thin filmdigital data storage medium of claim 29 further including a transparent,protective hard coat formed on the first surface of the support layer.42. The thin film digital data storage medium of claim 29 furtherincluding a transparent, protective hard coat formed on the secondsurface of the thin film data layer.
 43. The thin film digital datastorage medium of claim 29 further including a first transparent,protective hard coat formed on the first surface of the support layerand a second transparent, protective hard coat formed on the secondsurface of the thin film data layer.